Barrier cable coupler

Abstract

A barrier cable coupler for coupling two lengths of barrier cable comprises a coupler body including a threaded inner surface, a first end, and a second end; a fixed retaining collar having an outer surface and being retained to the first end of the coupler body, the fixed retaining collar including a tapered inner surface; one or more fixed end wedges positioned within the tapered inner surface of the fixed retaining collar; a tensioning retaining collar having an outer surface, the tensioning retaining collar positioned at least partially within the second end of the coupler body and including a tapered inner surface; one or more tensioning end wedges positioned within the tapered inner surface of the tensioning retaining collar; and a tensioning nut including a threaded outer surface engaging the threaded inner surface of the second end of the coupler body and retaining the tensioning retaining collar therein.

What is claimed is: 
     
       1. A method of forming a barrier cable assembly comprising:
 a) providing a first barrier cable length and a second barrier cable length, each cable length having an end; 
 b) providing a barrier cable coupler comprising:
 1) a coupler body having an inner surface, an outer surface, a first end, and a second end; 
 2) a fixed retaining collar, the fixed retaining collar having an outer surface, the fixed retaining collar retained to the first end of the coupler body, the fixed retaining collar including a tapered inner surface; 
 3) one or more fixed end wedges positioned within the tapered inner surface of the fixed retaining collar; 
 4) a tensioning retaining collar, the tensioning retaining collar having an outer surface, the tensioning retaining collar positioned at least partially within the second end of the coupler body, the tensioning retaining collar including a tapered inner surface; 
 5) one or more tensioning end wedges positioned within the tapered inner surface of the tensioning retaining collar; 
 6) a tensioning nut, the tensioning nut including a threaded outer surface engaging a threaded inner surface of the second end of the coupler body and retaining the tensioning retaining collar therein; 
 
 c) inserting the end of the first length of barrier cable into the first end of the coupler body such that the end of the first length of the barrier cable enters the fixed retaining collar and engages the one or more fixed end wedges; 
 d) inserting the end of the second length of barrier cable into the second end of the coupler body such that the end of the second length of the barrier cable enters the tensioning retaining collar through the tensioning nut and engages the one or more tensioning end wedges; and 
 e) advancing the tensioning nut into the coupler body by rotating the tensioning nut using a tensioning wrench that extends into the coupler body. 
 
     
     
       2. The method of  claim 1  wherein step e) applies tension to at least one of the lengths of barrier cable. 
     
     
       3. The method of  claim 1 , further including a step of preventing rotation of the fixed retaining collar relative to the coupler body by at least partially threading the fixed retaining collar into the coupler body and securing a jam nut to the fixed retaining collar. 
     
     
       4. The method of  claim 1  wherein the tensioning retaining collar has an outer surface that is not threaded and step e) includes sliding the tensioning retaining collar into the coupler body. 
     
     
       5. The method of  claim 1  wherein the outer surface of the fixed retaining collar is threaded and engages the threaded inner surface of the coupler body. 
     
     
       6. The method of  claim 1  wherein at least one of the first and second coupler body ends further comprises:
 an end spring cap retained within the coupler body; and 
 an end spring in compression between the end spring cap and the one or more fixed end wedges. 
 
     
     
       7. The method of  claim 6  wherein the end spring cap further comprises a threaded fastener. 
     
     
       8. The method of  claim 6  wherein the end spring cap is not threaded and engages the inner surface of the coupler body by friction. 
     
     
       9. The method of  claim 1  wherein the barrier cable coupler further includes a means for preventing rotation of the fixed retaining collar relative to the coupler body. 
     
     
       10. The method of  claim 9  wherein the means for preventing rotation is a lock nut. 
     
     
       11. The method of  claim 1  wherein the coupler body has an outer surface and a cross-section that is square, hexagonal, partially square, or partially hexagonal. 
     
     
       12. The method of  claim 11  wherein the outer surface includes one or more outer surface gripping features. 
     
     
       13. The method of  claim 1  wherein the outer surface of the tensioning retaining collar is not threaded. 
     
     
       14. The method of  claim 1  wherein the tensioning nut includes a driving head. 
     
     
       15. A method of forming a barrier cable assembly comprising:
 a) providing a first barrier cable length and a second barrier cable length, each cable length having an end; 
 b) providing a barrier cable coupler for coupling two lengths of barrier cable, the barrier cable coupler comprising:
 a coupler body having a bore therethrough; 
 first and second retainer assemblies, each retainer assembly including:
 a retainer bolt, each retainer bolt having a threaded extension extending into the bore of the coupler body; 
 a retainer collar mechanically coupled to the respective retainer bolt, each retainer collar including a tapered inner surface; and 
 one or more wedges positioned within each of the retainer collars; 
 wherein the threaded extension of the first retainer assembly is threaded in a first direction and the threaded extension of the second retainer assembly is threaded in a second direction; and 
 
 a tensioning nut, the tensioning nut threadedly coupled to the threaded extensions of the first and second retainer assemblies, the tensioning nut including inner threaded surfaces corresponding with the threads of the corresponding threaded extensions such that rotation of the tensioning nut moves the first and second retainer assemblies into the interior of the coupler body; 
 
 c) inserting the end of the first length of barrier cable into the first end of the coupler body such that the end of the first length of the barrier cable enters a retainer collar and engages one or more wedges; 
 d) inserting the end of the second length of barrier cable into the second end of the coupler body such that the end of the second length of the barrier cable enters a retainer collar and engages one or more wedges; and 
 e) rotating the tensioning nut. 
 
     
     
       16. The method of  claim 15  wherein the coupler body bore further comprises a longitudinal slot and each retainer bolt further comprises a tab in engagement with the slot. 
     
     
       17. The method of  claim 15  wherein the tensioning nut further comprises a square or hexagonal outer surface and the coupler body further comprises a cut-out positioned to allow access to the outer surface of the tensioning nut for rotation of the tensioning nut. 
     
     
       18. The method of  claim 15  wherein the tensioning nut further comprises external gear teeth and the coupler body further comprises a worm screw hole and a worm screw positioned therein, the worm screw engaging the external gear teeth of the tensioning nut. 
     
     
       19. The method of  claim 15  wherein at least one retainer assembly further includes at least one spring positioned between the retainer bolt and the retainer wedge so as to urge the retainer wedge into the retainer collars.